Wall-board and process of manufacturing the same



1. F. MAKOWSKI.

WALL BOARD AND PROCESS OF MANUFACTURING THE SAME.

APPLICATION FILED SEPT. 7, 1917-.RENEWED DEQ. 29,1919. I

4 SHEETS-SHEET I.

y u I Patfinted Aug. 17,

A TTORNE Y.

J. F. MAKOWSKI.

WALL BOARD AND PROCESS OF MANUFACTURING THE SAME.

APPLICATION FILED SEPT. 1, 1917. RENEWED nae-29.191

1,349,778. Patented Aug. 17,1920,

4 SHEETS-SHEET 2. fli gja c A TTORNE Y.

' IN VEN TOR.

JOHN F. MAKO wsK/ .I. F. MAKOWSKI.

WALL BOARD AND PROCESS OF MANUFACTURING THE SAME. APPLICATION FILEDSEPT-7,1917. RENEWED Dec. 29, 1919.

1,349,778. A Patented Aug. 17,1920.

4 SHEETS-SHEET 3.

11v VENTOR. obi/IV fTMMows/r/ BY A TTORN Y.

J. F. MAKOWSKI.

APPLICATION FILED SEPT. 7, 1917. RENEWED DEC. 29: 1919.

1,349,778. at ed Aug. 17, 1920.

a i k G J WITNESSES.

A TTORNEY.

1N VEN TOR.

g 5/ JOHN E MAKOWSK/ ""2 BY s \\\\\\\\\i' W 1,349,778. Application filedSeptember 7, 1917, Serial No. 190,131. Renewed December 29, 1919. SerialNo. 38,0 14..

un -TED STATES PATENT OFF-ICE,

JOHN F. unxowsxr, or SAN rnnivcrsco, CALIFORNIA, assrenon oFoNE-HALF ToJAMES A, LEVENSALEB, OF SAN FRANCISCO, CALIFORNIA.

WALL-BOARD AND PROCESS OF MAKUFAGTURING THE SAME.

To all whom it may concern: Be it known that I, JOHN F. MAKowsKI',

a citizen of the United States, and a resident of the cit and county ofSan Francisco, State of alifornia, have made a new and usefulImprovement in Wall-Boards and Processes of Manufacturing the Same;

lll)

and I do hereby declare the following to be a full, clear, concise, andexact description of the same.

The invention relates to a new and useful art particularly to means forperforating stable or dry wall board; and to the process of formingholes or recesses therein adapted to act as key holes for bondingfinishing Specification of Letters Patent.

plaster coats applied to the wall board, and

to a new article of manufacture.

Among the objects of this invention are to provide means foreconomically and effectively processing a wall board of the na turedescribed, to produce a new article of manufacture with improvedqualities and at greatly reduced cost of production; to produce a wallboard to which the finishing plaster can be applied and securely 'keyedwith the minimum'amount of plaster and waste, and to produce a wallboard fire and water proof-on the side opposite to that to which theplaster is applied. Other objects and advantages will appear as thedescription progresses.

In this specification and the annexed drawings, the invention isillustrated in the form considered to be the best, but it is to beunderstood that the invention is not limited to such form because it maybe embodied in other forms, and it isalso to be understood that in andby the claims following the description, it is desired to cover theinvention in whatever form it may be embodied.

In the accompanying four sheets of drawin s:

matic perforating machine constructed in accordance with this invention.

. Fig. 2 is a front view of the same.

Fig. 3 is-a side elevation detail in crosssection of the perforatingmechanism on the lin III-III of. Fig. 2.

of one side of the machine illustrating the punch operating mechanism incross-section on the line IV- IV, Fig. 1.

igure 1 is a side elevation of an auto- F "g. 4 is a fragmentaryenlarged detail matically illustrating the PatentedAug. 17, 1920.

Fig.5 a plan view from above of the same taken on the line V-V-, Fig. 1.

F 1g. dis a front elevation of the punching ing the laminated structureof the .Wall

board.

Fig. 11 is a fragmentary detail diagramintegral hey formed on thecoating" of plaster when a plied to the wall-board as it would remainwere the wall board removed.

Fig. 12 is a fragmentary detail cross section of a hollow punch. 1

F ig. 13 is detail similar to Fig. 10, illustrating the form of recessformed by the hollow punch.

Broadly stated, the process of producing plaster wvall board consists inflowing the plastic core composed of gypsum or other compositions in theunstable state, between tWo reinforcing sheets of prepared pulp 'paper,then rolling or pressing it into flat sheets, resulting in a-core X ofplaster faced on both sides by the sheets of paper X-X the whole forminga sheet of uniform thickness throughout, that is trimmed to size andthrough, such holes being uniform in cross section and having parallelsides.

In the process of forming plaster wall permitted to set or season beforebeing mar boards in accordance with this invention, the dry orstabilized board is passed through a machine wherein it is punched, thepunched portion being removed entirely from the board, as will behereinafter more fully described.

In detail the construction illustrated in the drawings consists of anautomatic punch ing machine, adaptable to processing wall board inaccordance with this invention, having a bed 1 supported upon a suitablebase 2, to which the upright sides 3-3 are bolted on opposite sides ofthe bed. The reciprocating breastbeam 4 engages these guides 3 and isguided thereby in its vertical reciprocations. The cam shaft 5 issuitably journaled in bearings supported by the guides 3-3 and providedwith the eccentrics 6 (see Fig. 4) engaged by the adjustable connectingrod 7 pivoted at 8 in the breast beam 4, whereby the rotation of thecamshaft 5 causes the vertical reciprocation of the breast beam 4. Thecam shaft is back-geared through the gear 9 enmeshed with the drivingpinion 10, fixed on the drive shaft 11, which is provided with a pulleyl2 driven by the belt 13 engaging a pulley on the motor 14, the propergearing being in terposed between the motor and the cam shaft to givethe necessary power and speed reduction. The breast beam 4 is providedwith a series of alined'male punches 15, fixed therein and cooperatingwith the female dies 16,- to perforate the plaster board 17 settherebetween. To reduce the applied power necessary to perforate theboard, and to prevent possible transverse cracking thereof in thepunching process, it is advisable to arrange the male punches so thatthey perforate the board serz'atz'm; this is easily accomplished byprogressively lengthening the punches from the center to the edge as isillustrated in Fig. 6 or vice versa, the length being varied from thecutting edge to the tapered shoulder at 18, so that these shoulders willall strike the board simultaneously. It is important that theseshoulders all strike the board simultaneously to bevel the edges of theholes by compression, whereby the resultant holes are. of

greater diameter at one surface of the board than atthe opposite side,for reasons that will hereinafter be described. Two rows of punches canbe provided-as illustrated in Fig. 3, arranged in off-set relation outof longitudinal alinement and placed a uniform distance apart, the boardbeing fed forward the space of two rows of holes at each operation.

The intermittent feeding mechanism comprises the two traction rollers19'and 20 between which the plaster board 17 is fed.

These traction rollers are fixed upon their respective shafts 21--22 andare rotated in unison by the gears '2324. The shaft 21 is 65 rotated bya ratchet 25 fixed thereon engaged by the pawl 26, pivoted on the arm 27formed on the hub 28 rotatable on the shaft 21. The hub 28 is operatedby the cable 29 wrapped therearound and having its opposite ends fixedto the lever 30 and the frame of the machine at 31 respectively. Thelever is pivoted at 32 and rests upon the cam fixed on the shaft 5. Thecam 33 is so timed that the rise of the punches out of the board, bringsthe cam under the lever 30 which is raised thereby, which exerts a pullon the cable 29 to rotate the hub 28 which carries the ratchet 25forward to rotate the traction wheels 19 and 20, pushing the boardforward a distance equal to the distance between the transverse rows ofholes. This distance may be accurately regulated by varying the positionon the lever 30 at which the cable 23) is attached.

When the cam 33 has passed underneath the lever 30 the tension of thespring 34 returns the arm 27 to the operative position for the nextoperation, the ratchet 26 return ing without engaging the ratchet.

The board 17 laid on the receiving table 35 is supported on the rollers36 from which it is conveniently fed between the feed rollers l9 and 20beneath the punching machine and ejected onto the delivery table 37.

In producing the type of board illustrated in Fig. 9 having the backingsheet placed thereon, means are provided in connection with the punchingmachine to apply this sheet as the board passes through the machine. Itis best accomplished by providing the sheet 38 in rolls as at 39, Figs.1 and 2, mounted upon a cross shaft 40 suitably journaled in asuperstructure on the machine. The sheet 38 is fed behind the roller 41,over the top of the roller 42 and carried down to contact with the topface of the board. The roller 42 is journaled in the trough 43containing paste submerging the lower portion of the roller 42, by whichmeans a coating of paste "is transferred to the surface of the paper 38tractivily passing over the roller 42. Before reaching the deliverytable 37, the board 17 passes between the compression rollers 44 and 45,geared together and driven by the sprocket chain 46 engaging a "sprocket47 on the shaft 21 of the feed rol 19, whereby these compression rollsoperate in unison with the feed roll. In starting, the end'of the paper38 is carried down in front of the rolls 44 and between which it ispushed by the approaching end of the board 17 on its travel through themachine. The roll 44 presses the paper 38 against the upper surface ofthe board 17 to which it is caused to adhere by the paste covering oneside of the holes 48 to form recesses in the through the hole 48 in theboard 1 7. Where it is desired to produce a laster board having theadvantagesas set orth, plus the additional advantages of beingfire-proof, the paper 38 can be treated with suitable fireproofingsolution, or it may be composed of asbestos 'or another non-inflammablematerial, by which means the plaster board having a non-inflammable backand a coating of non-inflammable plasteron the opposite side forms afire proof wall or partition. So'far as I am aware I' am the first toproduce sucha wall in this manner.

. To improve the keying qualities of the hole 48, they are countersunkby the tapered shoulder 18 on the male punches aspreviously described,producing a hole smaller in diameter on the plaster side of the boardthan on the back which is covered by the a sheet 38. This results informing a key integral with the plaster Y and taking the form Y asillustrated in Fig. 11, the form of the hole forming a clench orrivet-like v bond between the plaster Y and the wall board 17, inaddition to the natural adhecomprisingflowing a core of plastic matesionbetween the plaster and the surface of the wall board between theopenings, the dove-tail shape of the key Y insuring a mechanical bond inaddition to its adhesion to the surroundin tersinking of the oles hasthe further advantage that it can be made to fracture or shatter the'adjacent plaster-core to improve the keying qualities of the bond;part'ic'u larly where small, straight, or inclined holes are punched.The punches may be of forms to punch holes of any desired shape and theholes may be variously spaced.

' In Fig. 12 is illustrated a hollow r-X' and the core X leaving theaper punch li s the punching 51 out of the wall board. This punching 51is ejected from the punch by the stripper 52 actuated by the expansionof the spring53, the stripper being held in assembly by the slots 54engaging the screws 55 inv the punch 50; this form of punch formsa'recess such as 56, see Fig. 13. If it isdesired in addition topuncture the paper backingXa's at 57 the punch 58 can be combined withthe punch 50 tocoiiperat'e with the die 59 to punch the hole 57, whichpermits the. plaster coating his hollow type of punch is desirable whenthe wall board is to be treated in. the

wall board. The coununch 50 adapted to be forced into the wall oard assthrough 'thejwall board andlclench.

ter it, has set or dried, in which stable state it is more easilyprocessed and produces a superior article for the purpose; I do notwish'to be understood as limiting this invention thereby, as it can bepunched during its various stages of production or curing with variousresults.

Having thus described this invention, what I claim and desire to secureby ,Letters Patent is: p

1. A process of manufacturing wall board comprising flowing a core ofplastic material between reinforcing sheets of paper, allowing the sameto stand until dry, and then punching holes through the completed board.

2. A process of manufacturing wall board comprising flowing a core ofplastic material between reinforcing sheets of paper, pressing the sameinto fiat sheets, allowing said sheets to stand until dry, and thenpunching holes through the dry sheets.

3. A process of manufacturing Wall board comprising flowing a core ofplastic material between reinforcing sheets of paper, al-. lowing thesame to stand until dry, and then punching tapered holes through the dryboard.

4. A process of manufacturing wall board sion.

. 5. A process of manufacturing wall board comprising flowing a core ofplastic material between reinforcing shets of paper, allowing the sameto stand until dry, and then punching holes through the dry board insuch manner as to shatter the substance of the board adjacent to thehole.

6. The process of treatin dry wall board consisting in punching ho estherethrough and covering one side of said holes to form a recess insaid wall board.

7 An article of manufacture consisting of a sheet of wall board composedof a core of dry plaster between reinforcing sheets having holes punchedtherethrough while in the dry state, and a sheet of fire proof materialapplied to one side ofsaid board after said punching operation.

- In testimon whereof I have hereunto set my hand at 7th day of August,1917.

JOHN F. MAKOWSKI.

an Francisco, California, this

